Connectors for flexible busbar and methods of connecting

ABSTRACT

A connector for a flexible busbar is provided. The connector includes a jaw and a relief. The jaw has a first member and a second member both depending from a support member and spaced from one another by a distance. The distance is larger than a thickness of the flexible busbar. The relief is defined on first member and/or second member. The jaw is deformably compressible onto the flexible busbar upon application of a deformation force on the first and second members so that the flexible busbar conforms to the at least one relief to form an electrical and mechanical connection.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 16/455,203filed Jun. 27, 2019, now pending, which is a continuation of U.S.application Ser. No. 15/075,510 filed Mar. 21, 2016, which issued asU.S. Pat. No. 10,361,491 on Jul. 23, 2019, which claims the benefit ofU.S. Provisional 62/137,130 filed Mar. 23, 2015, the entire contents ofall of which are incorporated by reference.

BACKGROUND 1. Field of the Disclosure

The present disclosure is related to connectors for flexible busbars.More particularly, the present disclosure is related to deformablycompressible connectors for flexible busbars and methods of connecting.

2. Description of Related Art

Busbars are metal conductors that are used in electrical systems suchas, but not limited to, switch gear, panel boards, distribution boards,and the like. When the busbars are flexible busbars, they are typicallyformed of a number of conductive layers. Further, when a busbar isflexible, it can be used for power distribution in a manner analogous toa conventional round conductor.

The busbars are terminated or secured using hardware. Installation canbe time consuming and cumbersome for the installer for several reasons.During installation a hole is often made in the busbar using, forexample, a drill or a hole punch. Next, the busbar is fastened to theintended fixture using hardware. Finally, the hardware is then tightenedsuch that the busbar is able to adequately conduct electricity whilesimultaneously resisting a certain pull out force and remaining securelyattached.

Flexible busbars are often installed into tight enclosures. Because ofthe complexity and numerous steps required for installing busbars,sufficient clearance in the installation area is required so that theinstaller can operate the tools necessary for the installation.

Accordingly, there is a need for connectors for flexible busbars thatovercome, alleviate and/or mitigate one or more of the aforementioned orother defects and deficiencies of prior art busbar connectors.

SUMMARY

A connector for a flexible busbar is provided. The connector includes ajaw and a relief. The jaw has a first member and a second member bothdepending from a support member and spaced from one another by adistance. The distance is larger than a thickness of the flexiblebusbar. The relief is defined on first member and/or second member. Thejaw is deformably compressed onto the flexible busbar upon applicationof a deformation force on the first and second members so that theflexible busbar deforms, thus conforming to the at least one relief toform an electrical and mechanical connection.

In embodiments alone or in combination with one or more of the aftmentioned embodiments, the jaw is made of a material that is harder thana material of the flexible busbar.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the jaw has a length along a first axis and awidth along a second axis.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the width of the first and/or second memberis from 35% to 140% of a width of the flexible busbar.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the relief is disposed along the first axisor the second axis.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the relief is disposed at an intersection ofthe first member and/or second member and the support member so that therelief functions as a weakened area for deformable compression of thejaw.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the connector also includes a lug dependingfrom the support member along the first axis.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the relief comprises two reliefs on the firstmember and three reliefs on the second member. The reliefs on the firstand second members being axially offset, along the first axis, from oneanother.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the connector further includes a guide on anouter surface of the first member and/or the second member. The guide isconfigured for receiving and collocating an indenter die to ensure thedesired deformable compression of the jaw onto the flexible busbar.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the guide is disposed along the first axis.

A busbar assembly is also provided that includes a flexible busbar, ajaw, and a relief. The flexible busbar includes a plurality ofelectrically conducting layers stacked upon one another to provide athickness. The jaw has a first member and a second member both dependingfrom a support member and spaced from one another by a distance. Thedistance, before deformable compression, is larger than the thickness ofthe flexible busbar. The relief is on the first member and/or secondmember. The jaw is deformably compressed onto the flexible busbar uponapplication of a deformation force on the first and second members sothat the flexible busbar conforms to the at least one relief to form anelectrical and mechanical connection.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the assembly further includes insulationdisposed on at least a portion of the flexible busbar.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the jaw is made of a material that is harderthan a material of the flexible busbar.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the jaw is an extruded member.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the jaw has a length along a first axis and awidth along a second axis.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the width of the first and/or second memberis from 35% to 140% of a width of the flexible bus bar.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the relief is disposed at an intersection ofthe first member and/or second member and the support member so that therelief functions as a weakened area for deformable compression of thejaw.

A method for connecting connector and a flexible busbar is provided thatincludes inserting the flexible busbar having a plurality of stackedconducting layers between first and second members of the connector; andapplying a deforming force onto the connector sufficient to deformablycompress the first and second members onto the flexible busbar so thatthe flexible busbar deforms and conforms to at least one relief in thefirst member and/or second member to form an electrical and mechanicalconnection.

In embodiments alone or in combination with one or more of the afore oraft mentioned embodiments, the plurality of stacked conducting layersslide with respect to one another during conformance of the flexiblebusbar to the at least one relief.

The above-described and other features and advantages of the presentdisclosure will be appreciated and understood by those skilled in theart from the following detailed description, drawings, and appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of an exemplary embodiment of adeformably compressible connector according to the present disclosure;

FIG. 2 is a side perspective view of the connector of FIG. 1;

FIG. 3 is side view of a flexible busbar for use with the connector ofFIG. 1;

FIG. 4 is a side view of the connector of FIG. 1 after connection to theflexible busbar of FIG. 2;

FIG. 5 is an enlarged view of the assembly of FIG. 4;

FIG. 6 is a perspective view of an exemplary embodiment of a die setaccording to the present disclosure for use with the connector of FIG.1;

FIG. 7 is a side view of the top die of FIG. 6 in use with the connectorof FIG. 1;

FIG. 8 is a front view of the top die of FIG. 6 in use with theconnector of FIG. 1; and

FIGS. 9-15 are perspective views of alternate exemplary embodiments ofconnectors according to the present disclosure.

DETAILED DESCRIPTION

Referring to the drawings and in particular to FIGS. 1 through 5, anexemplary embodiment of a deformably compressible connector according tothe present disclosure is shown and is generally referred to byreference numeral 10. Advantageously, connector 10 is configured to bedeformably compressed onto and, thus, secured onto a flexible busbar 12in an electrically conductive and mechanically robust manner.

Connector 10 includes a lug 14 and a deformably compressible jaw 16having a first member 18 and a second member 20 both depending from asupport member 22. Jaw 16 is configured to be compressed by applicationof a deformation force (F_(d)) so that first and second members 18, 20are deformably compressed onto flexible busbar 12 with the flexiblebusbar mechanically and electrically connected to connector 10 in amanner resistant to pullout forces (F_(p)). As used herein, the pulloutforce (F_(p)) is defined as a force along first axis 24 (FIGS. 3 and 4)and/or second axis 26 (FIG. 3) necessary to disengage or to dislodgebusbar 12 from connector 10.

Connector 10 is configured so that, during compression of jaw 16, thejaw deformably compresses at least one of first member 18, second member20, and support member 22.

Busbar 12 includes a plurality of electrically conducting layers 28stacked upon one another to provide a desired thickness 30 and, whendesired, an insulation 32 along first axis 24. It is contemplated by thepresent disclosure for the individual layers 28 of busbar 12 can have acommon thickness or for the layers to have different thicknesses. By wayof non-limiting example, thickness 30 can be between 1 and 100millimeters (mm), preferably between 5 and 55 mm, with between 10 and 30mm being most preferred, and any subranges therebetween. The number ofindividual layers 28 of busbar 12 can also vary, from a single layer tothirty layers.

Further, busbar 12 has a centerline C_(L) along axis 24. Owing to itsnovel structure, the connectors according to the present disclosuredeform busbar 12 through and including centerline C_(L). Stated anotherway, all of the layers 28, including the centermost layer, deform.

When insulation 32 is present, the insulation is removed at ends ofbusbar 12 to provide exposed ends of at least a length 34 along firstaxis 24 and a width 36 along second axis 26 that allows for mechanicaland electrical connection with connector 10. Additionally, insulation32, when present, can at least assist at maintaining layers 28 instacked alignment.

Connector 10 includes one or more reliefs 38 (two shown) defined withinjaw 16 on first and/or second member 18, 20. In the illustratedembodiment, reliefs 38 are illustrated on second member 20. Of course,it is contemplated by the present disclosure for reliefs 38 to be onlyon first member 18, only on second member 20, or on both the first andsecond members. Additionally, reliefs 38 are illustrated in theexemplary embodiment as being along second axis 26. Of course, it iscontemplated by the present disclosure for reliefs 38 to be along firstaxis 24, along second axis 26, along both first and second axes, angledwith respect to either the first or second axis, and any combinationsthereof.

Moreover, it should be recognized that reliefs 38 are illustrated ascontinuous across the entire extent of second member 20. However, it iscontemplated by the present disclosure for reliefs 38 to be continuous,discontinuous, or any combinations thereof.

Relief 38 can have any desired cross-sectional shape such as, but notlimited to, polygonal or curved. Additionally, relief 38 can be concave,convex, any combinations thereof. In the illustrated embodiment, relief38 has a semi-circular concave cross section.

Connector 10 is further configured so that at least one of relief 38 islocated at the intersection of second member 20 and support member 22.In this manner, relief 38 acts as a weakened area for deformablecompression of jaw 16.

Advantageously, it has been determined by the present disclosure thatproviding busbar 12 with individual layers 28 allows the layers todeform and slide along at least first axis 24 with respected to oneanother when connector 10 is deformably compressed onto the busbar.Stated another way, it has been determined that flexible busbar 12, dueto layers 28, is particularly suited for deformation within connector10.

Moreover, and without wishing to be bound by any particular theory, itis believed that connector 10 should be made of a material that isharder or less malleable than the material of busbar 12, which isbelieved to allow layers 28 to slide over one another and allow thebusbar to deform and flow into reliefs 38. Simply stated, connector 10is configured to deformably compress at jaw 16—namely at first member18, second member 20, support member 22, and any combinations thereof—sothat busbar 12 conforms to the peaks and valleys formed by reliefs 38.Certain embodiments like connector 610, shown in FIGS. 4 and 14 alsohave an indenter which concentrate the deformation force (not shown) onthe flexible busbar (not shown) such that the flexible busbar deformsand conforms to reliefs vertically aligned therewith.

Connector 10 can, in some embodiments, also include one or more guides40 (two shown) formed by a relief, channel, trough, or indentation on anouter surface of first member 18. In the illustrated embodiment, guides40 are illustrated on first member 18. Of course, it is contemplated bythe present disclosure for guides 40 to be only on second member 20,only on first member 18, or on both the first and second members. Aswill be described in more detail below, guides 40 are configured forreceiving and collocating an indenter die to ensure the desireddeformable compression of jaw 16 onto busbar 12.

Additionally, guides 40 are illustrated in the exemplary embodiment asbeing along second axis 26—and/or along the same axis as guides 38. Ofcourse, it is contemplated by the present disclosure for guides 40 to bealong first axis 24, along second axis 26, along both the first andsecond axes, angled with respect to either of the first or second axes,and any combinations thereof. Further, it is contemplated by the presentdisclosure for guides 40 to be parallel to reliefs 38, perpendicular tothe reliefs, angled with respect to the reliefs, and any combinationsthereof.

Moreover, it should be recognized that guides 40 are illustrated ascontinuous across the entire extent of first member 18. However, it iscontemplated by the present disclosure for guides 40 to be continuous,discontinuous, or any combinations thereof. Guides 40 can have anydesired cross-sectional shape such as, but not limited to, polygonal orcurved.

Lug 14 can, in some embodiments include a bore 42 therethrough forsecuring connector 10 with conventional fastening hardware to a circuitor other component. In this manner, connector 10, after deformablecompression of jaw 16 and deformation of flexible busbar 12, can be usedto terminate the busbar and pass electrical current from the flexiblebusbar to a desired mounting surface connected to lug 14. Bore 42 has,optionally, a thread, a countersink, and/or a counterbore.

However, owing to its unique design, connector 10 according to thepresent disclosure deforms flexible busbar 12 onto which the connectoris connected. In certain preferred embodiments, connector 10 accordingto the present disclosure deforms flexible busbar 12 through acenterline C_(L) of the flexible busbar, and onto which the connector isconnected Advantageously and unlike prior art conductors, flexiblebusbar 12 does not expand outwardly when deformed, thus maintaining itsoriginal width prior to deformation. Rather, layers 28 deform and slideover one another along first axis 24 so as to conform to reliefs 38.Such configuration unexpectedly yields an improved contact betweenconnector 10 and busbar 12. Consequently, increased pullout values areachieved by connector 10 as compared to prior art connectors.

Connector 10 has a length 44 along first axis 24 and a width 46 alongsecond axis 26. In some embodiments, width 46 of connector 10 is from35% to 140% of width 36, preferably from 75% to 105%, and with 80% to100% being most preferred, and any subranges therebetween. Inembodiments where width 46 is less than 75%, first and second members18, 20 can have a thickness that is increased from 5% to 20% toaccommodate for less conducting material of present in busbar 12 withinjaw 16, as compared to larger widths.

Connector 10 has a distance 48 between first and second members 18, 20,which depend on thickness 30 of flexible busbar 12. Accordingly, beforecompression, distance 48 between first and second members 18, 20 shouldbe larger than thickness 30 by no more than 30%, with no more than 20%being preferred, and no more than 10% being most preferred.

Connector 10 is, in some embodiments, an extruded member that allows forrapid manufacturing and efficient use of materials contributing to lesswasted material. Once formed as an extrusion, connector 10 can betrimmed or cut from the extrusion to width 46. Of course, it iscontemplated by the present disclosure for connector 10 to be made byany desired method such as, but not limited to, molding, machining,additive manufacturing, stamping and welding, and others. In somepreferred embodiments, connector 10 is formed as a single piececonstruction.

Connector 10 is made of any material having sufficient strength,hardness, malleability, and electrical conductivity for the desiredapplication. In some embodiments, connector 10 is made a metal such as,but not limited to steel, iron, aluminum, copper, silver, gold, andalloys thereof. Additionally, it is contemplated by the presentdisclosure for connector 10 to be made of any desired material and tofurther include a coating (not shown) on at least the surfaces thatcontact busbar 12.

Although connector 10 is described herein by way of example in use withflexible busbar 12 having layers 28, it is also contemplated by thepresent disclosure that the connector 10 finds equal use with busbarshaving only a single layer of conductor. It should also be understoodthat connector 10 can also be deformably compressed onto busbars,flexible or otherwise, having ends that are non-rectangular in shape.

Three samples of the connector were tested, each having a samplehardness of Rockwell F 82 max. Each was tested to determine a pulloutvalue after the jaws were deformably compressed onto a flexible busbar.Results are summarized in Table 1 below. Ratings were given to eachembodiment based on whether the particular connecter failed or passed,with connectors passing being further rated as good, better, or best.Each was used in conjunction with a differently sized flexible busbar12, which was annealed to a 38 F scale hardness.

TABLE 1 Flexi Sample bus kcmil UL LBF Pullout # Embodiment SizeEquivalent Requirement Value 1 See, e.g. FIG. 13 1 × 40 × 10 789.41 for700-2000 kcmil Pass - Good 2 See connector 10, e.g., it is 1000 lbfPass - Better right hand side of FIG. 4 with bottom relief 3 Seeconnector 610, e.g. FIG. 14 Pass - Best See connector 610, e.g., lefthand side of FIG. 4 with bottom relief and top indenter

Advantageously, the assembly of flexible busbar 12 and one or moreconnectors 10 and 610 (described below), as shown in the figures,provide a simple structure that is resistant to the pullout forces(F_(p)) in an easily repeatable manner.

Turning now to FIGS. 6-8, connector 10 is shown in use with an indentordie set 50. Die set 50 includes a first die 52 and a second die 54.Here, first die 52 is configured for contact with first member 18, whilesecond die 54 is configured for contact with second member 20.

First die 52 has one or more indenting protrusions 56 (two shown), whichare configured for mating with guides 40 on an outer surface of firstmember 18 of jaw 16, while second die 54 has a flat surface 58 formating with an outer surface of second member 20 of the jaw. The matingof guides 40 and protrusions 56 are configured to ensure the desireddeformation from die set 50 is applied at a desired location of jaw 16so as to deform busbar 12 by deformably compressing connector 10thereon. In preferred embodiments, guides 40 are in vertical alignmentwith reliefs 38 along third axis 25. Protrusions 56 of indenting die 52thus align with guides 40 to concentrate a deformation force at reliefs38 in second member 20. In embodiments where reliefs are also present infirst member 18 such as shown in FIG. 14, the reliefs in first member 18are vertically offset with respect to the reliefs in second member 20and spaced apart by an indenter in first member 18 that verticallyaligns with the reliefs in second member 20 and guides 40.

In the illustrated embodiment, protrusions 56 are illustrated on firstdie 52 and along second axis 26 so as to mate with guides 40, which arepositioned on first member 18 and along second axis 26. Of course, it iscontemplated by the present disclosure for protrusions 56 to be only onsecond die 54, only on first die 52, or on both the first and seconddie, as well as along first axis 24, along second axis 26, along boththe first and second axes, angled with respect to either the first orsecond axis, and any combinations thereof—or as needed to conform to thelocation and position and size of guides 40 on first member 18 and/orsecond member 20.

It should be recognized that connector 10 is described above by way ofexample only. Alternate exemplary embodiments of the connector accordingto the present disclosure are shown in FIGS. 9-15 and having featuresperforming similar and/or analogous functions number in multiples of onehundred.

In the embodiment of connector 110 illustrated in FIG. 9, the connectorhas one or more reliefs 138 on both first and second members 118, 120,extending along second axis 126, and having a rectangular cross section.Advantageously, one or more indenters 139 concentrate the deformationforce (not shown) on the flexible busbar (not shown) such that theflexible busbar deforms and conforms to reliefs 138.

First member 118 is illustrated having two reliefs 138, while secondmember 120 is illustrated having three reliefs 138. Preferably, reliefs138 on first member 118 are offset by two indenters 139, along the firstaxis 124, with respect to reliefs 138 on second member 120. In thismanner, connector 110 is configured to increase the pullout value andholding force on the flexible busbar (not shown) by adjacent reliefs138. Stated another way, connector 110 is configured to prevent pinchpoints between adjacent reliefs 138 by ensuring a minimum offsettherebetween.

Connector 210 illustrated in FIG. 10, similar to connector 110 of FIG.9, has one or more reliefs 238 on both first and second members 218, 220and extending along second axis 226. First member 218 is illustratedhaving two reliefs 238 that are offset by indenters 239, along the firstaxis 224, with respect to the three reliefs 238 of second member 220 soas to increase the pullout value and holding force on the flexiblebusbar (not shown) by adjacent reliefs 238.

Instead of the rectangular cross section of FIG. 9, connector 210 hasreliefs 238 with a cross section that results in upstanding featureshaving a first surface 260, a second surface 262, and a third surface264. First surface 260 is a vertical planar surface that runs along axis226 and, thus, faces a direction opposite to the pullout forces on theflexible busbar (not shown) along first axis 224. Second surface 262 isa horizontal planar surface that also runs along second axis 226 and,thus, faces a direction towards first and second members 218, 220,respectively. Third surface 264 is an arcuate surface that provides agentle slope away from second surface 262 towards first and secondmembers 218, 220, respectively. In this manner, reliefs 238 have a crosssection that provides the upstanding features with a wave-lineappearance.

Connector 310 illustrated in FIG. 11 has one or more reliefs 338 on bothfirst and second members 318, 320 and extending along second axis 326.First member 318 is illustrated having two reliefs 338 that are offset,along the first axis 324 by indenters 339, with respect to the threereliefs 338 of second member 320 so as to increase the pullout value andholding force on the flexible busbar (not shown) by adjacent reliefs338.

Connector 310 has reliefs 338 with a cross section that results inupstanding features having a first surface 360, a second surface 362,and a third surface 364. First surface 360 is an arcuate surface thatruns along second axis 326 that provides a gentle slope away from firstand second members 318, 320, respectively, towards second surface 362.Second surface 362 is a horizontal planar surface that also runs alongsecond axis 326 and, thus, faces a direction towards first and secondmembers 318, 320, respectively. Third surface 364 is also an arcuatesurface that provides a gentle slope away from second surface 362towards first and second members 318, 320, respectively.

Connector 410 illustrated in FIG. 12 is substantially similar to thesemi-circular concave cross sectional relief 38 of connector 10 shown inFIG. 1. However in the embodiment of FIG. 12, connector 410 is shownhaving reliefs 438 extending along first axis 424, namely perpendicularto the embodiment of FIG. 1.

Connector 510 illustrated in FIG. 13 is shown, for ease of explanation,lacking any reliefs. Namely, first and second members, 510, 520 in jaw516 are flat. Here, connector 510 further includes one or more bores 566through jaw 516. Bores 566, similar to bore 542, allows connector 510 tobe secured with conventional fastening hardware to a circuit or othercomponent. Optionally, bores 566 and 542 can be threaded, countersunk,and/or counter bored. In this manner, connector 510, after deformablecompression of jaw 516 and deformation of the flexible busbar, can beused to terminate the busbar and pass electrical current from theflexible busbar to a desired mounting surface.

Connector 610 illustrated in FIG. 14, has one or more reliefs 638 onboth first and second members 618, 620, both depending from supportmember 622. Between reliefs 638 in first member 618 is an indenter 639.Indenter 639 is vertically aligned with guides 640 of first member 618and at least one of reliefs 638 of second member 620 along third axis625. Reliefs 638 are concave surfaces formed in the inner opposingsurfaces of first and second members 618 and 620 of jaw 616. Reliefs 638are spaced apart along first axis 624 and extend along second axis 626.Reliefs 638 in first member 618 are offset with respect to reliefs 638in second member 620 along first axis 624. Further guides 640 on anouter surface of first member 618 of jaw 616 are convex channelsextending along axis 626. Connector 610 has a tongue 614 similar to thatof connector 10.

Connector 710 illustrated in FIG. 15, is similar to connector 610 butalso has a feature 768 located at the intersection of support member 722and each of first and second members 718, 720. Feature 768 is a radiusextending along axis 726. Additionally, connector 710 has two indenters739 vertically aligned with the two reliefs in second member 720 and twoguides 740 in first member 718 along each third axis 725. Although shownin both first and second members 718, 720, feature 768 can also belocated in only one of first and second members 718, 720. Connector 710has one or more reliefs 738 on both first and second members 718, 720.Reliefs 738 are concave surfaces formed in the inner opposing surfacesof first and second members 718, 720 of jaw 716. Reliefs 738 are spacedapart along first axis 724 and extend along second axis 726. Reliefs 738in first member 718 are offset with respect to reliefs 738 in secondmember 720 along first axis 724. Further guides 740 on an outer surfaceof first member 718 of jaw 716 are convex channels extending along axis726. Connector 710 has a tongue 714 similar to that of connector 10.

It should be noted that where a numerical range is provided herein,unless otherwise explicitly stated, the range is intended to include anyand all numerical ranges or points within the provided numerical rangeand including the endpoints.

It should also be noted that the terms “first”, “second”, “third”,“upper”, “lower”, and the like may be used herein to modify variouselements. These modifiers do not imply a spatial, sequential, orhierarchical order to the modified elements unless specifically stated.

Although described herein with reference to one or more exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the presentdisclosure. In addition, many modifications may be made to adapt aparticular situation, construction, operation, or material to theteachings of the disclosure without departing from the scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular embodiment(s) disclosed as the best mode contemplated,but that the disclosure will include all embodiments falling within thespirt and scope of the appended claims.

What is claimed is:
 1. A method of connecting a connector to a flexiblebusbar, comprising: providing the connector; providing the flexiblebusbar as a stack of a plurality of electrically conducting layershaving a length along a first axis, a thickness along a second axis, anda width along a third axis; inserting, along the first axis, an end ofthe flexible busbar in a jaw of the connector so that the width and thethickness are in the jaw, the jaw being defined by an upper jaw memberand a lower jaw member that depend from a support member so as to bespaced from one another a distance along the third axis, the distancebeing larger than the thickness; and deformably compressing the upperand lower jaw members along the third axis onto the end of the flexiblebusbar so that the plurality of electrically conducting layers slideover one another along the first axis and conform to the jaw to form anelectrically conductive and mechanically secure connection between thejaw and the flexible busbar.
 2. The method of claim 1, wherein, afterthe deformably compressing step, the flexible busbar maintains the widthalong the second axis.
 3. The method of claim 1, wherein the step ofdeformably compressing comprises deforming all of the plurality ofelectrically conducting layers.
 4. The method of claim 1, wherein theconnector is made of a harder material than the flexible busbar.
 5. Themethod of claim 1, wherein the connector comprises a feature within thejaw on an inner surface of the upper jaw member and/or the lower jawmember.
 6. The method of claim 5, wherein the plurality of electricallyconducting layers conform to the feature.
 7. The method of claim 5,wherein the feature is a relief and/or an indenting protrusion.
 8. Themethod of claim 5, wherein the feature has a direction selected from agroup consisting of along the first axis, along the second axis, angledwith respect to the first axis, angled with respect to the second axis,and any combinations thereof.
 9. The method of claim 5, wherein thefeature has a position selected from a group consisting of at anintersection of the upper jaw member and the support member, at anintersection of the lower jaw member and the support member, offset froman intersection of the upper jaw member and the support member, offsetfrom an intersection of the lower jaw member and the support member, andany combinations thereof.
 10. The method of claim 5, wherein the featureis continuous or discontinuous.
 11. The method of claim 5, wherein thefeature has a cross-sectional shape selected from a group consisting ofa polygonal shape, a curved shape, a concave shape, a convex shape, andany combinations thereof.
 12. The method of claim 5, wherein theconnector further comprises an indenter guide on an outer surface of theupper jaw member and/or the lower jaw member.
 13. The method of claim12, wherein the indenter guide has a direction selected from a groupconsisting of along the first axis, along the second axis, angled withrespect to the first axis, angled with respect to the second axis, andany combinations thereof.
 14. The method of claim 12, wherein theindenter guide is aligned along the third axis with respect to thefeature.
 15. The method of claim 14, wherein the step of deformablycompressing comprises using an indenter aligned with the indenter guideto deformably compress the upper and lower jaw members along the thirdaxis.
 16. The method of claim 1, wherein the step of providing theconnector comprises: extruding the connector as an unitary extrudedmember from a metal, the unitary extruded member having a length alongthe second axis; and trimming or cutting the unitary extruded memberalong the first axis.
 17. The method of claim 16, wherein the metal isselected from a group consisting of steel, iron, aluminum, copper,silver, gold, and alloys thereof.
 18. The method of claim 1, wherein thestep of providing the connector further comprises: providing a lugdepending from the support member opposite from the upper and lower jawmembers along the first axis; and defining a bore through the lug alongthe third axis.
 19. The method of claim 1, wherein the distance betweenthe upper jaw member and the lower jaw member along the third axis is nomore than 30% larger than the thickness of the flexible busbar.
 20. Themethod of claim 1, wherein the distance between the upper jaw member andthe lower jaw member along the third axis is no more than 10% largerthan the thickness of the flexible busbar.